The Stages of DPF Cleaning

Stage 1 Pneumatic Cleaning

Pneumatic Cleaning

The TrapBlaster™ MAX, XL, JR, and CatBlaster™ 2P, are our pneumatic cleaners. The TrapBlaster™ MAX and TrapBlaster™ XL use our patented scanning air-knives, the TrapBlaster™ JR uses focused air scanning and the CatBlaster™ 2P is built specifically as a bi-directional pneumatic cleaner for closed-end filters.

The high pressured air removes soot and ash. about 80% of all DPFs are complete and green tag clean* after 30 minutes and are ready to be placed back on the vehicle, ready to go.

[The TrapBlaster™ JR will take longer than the other machines to clean and has been built for low volume shops.]

FSX Diagnostic Feature

Here at FSX we provide a diagnostic feature that will detect failed filters within the first two minutes of cleaning. Our bi-directional air knives provide immediate evidence of damaged cells and cracked filters. This feature is unique to the FSX pneumatic cleaners.

*Green tag – clean and ready to go back on the vehicle.

Stage 2 Thermal Cleaning

Thermal Cleaning

The TrapBurner™ 7, 8, and 10, are thermal regenerators are needed by one in every eight filters. These kilns heat the diesel particulate filters DPF) to oxidize any remaining soot and loosen hardened ash remaining after the Stage 1 cleaning. This process is not necessary for all DPFs. This process takes 12 hours and helps to process another 15% of DPFs, bringing the total to 95% of filters to green tag clean and able to be placed back into service after both Stage 1 & 2. While this stage is not needed by all filters, it will give the filter an out-of-the-box clean for clients who desire that.

Stage 3 Wet Cleaning

Wet Cleaning

Dealer/Workshop Level (low-volume) – 95% of DPF are cleaned to green tag range using Stage 1 and Stage 2 cleaning. Approximately 5% of DPF requires additional cleaning. For low volume applications, the TrapRinser™ can be utilized with the TrapSoak™ and chemical solutions to actively dissolve remaining ash plugs and scale, returning the DPF to near-new condition. The TrapRinser™ uses air knife-style knives to assist in flushing and safely rinses dissolved ash without the risk of hydraulic fracturing used by competitor pulse-based wet cleaners.

REMAN/OEM level (high-volume) – REMAN level cleaning builds upon the tools used at the dealer level to accommodate higher volumes and enhanced chemical cleaning, high-volume wastewater treatment, and targeted catalytic recovery. As each fleet and original engine manufacturer (OEM) needs are unique, please contact FSX for a system designed to your specifications. 

Note:  Wet Cleaning in place of Stage 1 Cleaning: It is possible to use the TrapRinser as a Stage 1 cleaner. The FSX TrapRinser is capable of being used to remove both loose soot and ash in similar fashion to competitor equipment. Using the TrapRinser as a Stage 1 cleaner will consequently result in the inability to detect breached DPFs; a unique feature only available in the TrapBlaster Stage 1 cleaner. Furthermore, wet cleaning prior to Stage 1 and 2 cleaning will decrease wastewater filtration system efficiency.

Ash – the solid remains of fire or combustion. In diesel engines, it comes from burned engine oil

Catalytic Converter – a device incorporated in the exhaust system of a motor vehicle, containing a catalyst for converting pollutant gases into less harmful ones

Diesel Particulate Filter (DPF) – is a device designed to remove diesel particulate matter or soot from the exhaust gas of a diesel engine

Hardened Ash – over time ash hardens and plugs the cell. This ash becomes difficult to remove. The longer ahs spends in the diesel particulate filter (DPF) the harder it is to remove. Without proper cleaning, this hardened ash will hinder performance and can lead to irreversible damage.